Dual-resin epoxy–phenolic composite bipolar plates with enhanced conductivity and strength for PEMFCs

A high-performance composite bipolar plate (CBP) was developed using a dual-resin matrix of epoxy (EP) and phenolic resin (PF) for proton exchange membrane fuel cells (PEMFCs). In-situ copolymerization of EP within the PF network significantly improved mechanical toughness, electrical conductivity, and corrosion resistance. The optimized CBPs exhibited flexural strength above 40 MPa, conductivity over 100 S·cm −1 , and a very low corrosion current density of 0.01 μA·cm −2 under simulated operating conditions. Beyond these technical achievements, this study contributed to UN Sustainable Development Goal 7 (Affordable and Clean Energy) by enabling cost-effective hydrogen energy technologies, and supported Goal 13 (Climate Action) through the promotion of low-carbon, high-efficiency fuel cell components. The proposed dual-resin strategy provided a scalable and environmentally aligned route for CBP fabrication, offering new insight into sustainable materials design for next-generation clean and renewable energy systems.